Granular welding flux delivery devices and strip cladding systems with granular welding flux delivery devices

ABSTRACT

Granular welding flux delivery devices and strip cladding systems with granular welding flux delivery devices are disclosed. A disclosed example granular welding flux delivery device includes a hopper having: an intake opening to receive granular welding flux; a chute; and an output opening to output the granular welding flux to an electroslag strip cladding process, a submerged arc welding process, or a submerged arc strip cladding process. The example granular welding flux delivery device further includes a chute divider positioned within the chute to reduce an intake rate of granular material through the intake opening by reducing a cross-section of the chute based on a dimension of the chute divider. The disclosed example granular welding flux delivery device includes an adjustable output cover attached to the chute proximate to the output opening to extend or retract a length of the chute by adjusting a location of the output opening along the chute.

RELATED APPLICATIONS

This application claims priority to IT Application No. 102016000043661having an International filing date of Apr. 28, 2016, which isincorporated herein by reference in its entirety.

BACKGROUND

The invention relates generally to welding systems and, moreparticularly, to strip cladding heads and strip cladding systems.

Cladding is a fundamental process to the manufacturing and fabricationindustries and is used across many applications, includingpetrochemical, oil and gas, pressure vessel and boiler making. Theprocess of cladding involves putting a new layer on top of an existingwork piece (e.g., to repair items such as nozzles, ball valves, millrolls and shafts) and/or to improve the wear resistance or corrosionproperties of the piece. Cladding methods include submerged arc stripcladding (SASC) and electroslag strip cladding (ESSC).

In conventional SASC, an arc runs along the width of the strip,depositing weld metal on the base material. Because there is penetrationinto the base material, dilution levels typically are about 20 percentwith SASC.

In conventional ESSC, the strip is fed through a delivery system muchlike wire is fed during a conventional wire welding process. Since ESSCis not an arc process, heating takes place in the conductive flux, andthe resulting heating effect melts the strip and base material into theliquid slag, which is then transferred into molten metal that isdeposited onto the base material. The strip rides on top of the slagsystem created by the flux, protecting the weld.

SUMMARY

Granular welding flux delivery devices and strip cladding systems withgranular welding flux delivery devices are disclosed, substantially asillustrated by and described in connection with at least one of thefigures, as set forth more completely in the claims. Disclosed examplesinclude both submerged arc cladding systems and electroslag stripcladding systems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating an example strip cladding systemin accordance with aspects of this disclosure.

FIG. 2 is a partially exploded view of an example implementation of thestrip cladding system of FIG. 1 in accordance with aspects of thisdisclosure.

FIG. 3 is a perspective view of an example implementation of thecladding head of FIG. 1, in accordance with aspects of this disclosure.

FIG. 4A is another view of the example cladding head of FIG. 3,illustrating an example spacing between the contact jaws, in accordancewith aspects of this disclosure.

FIGS. 4B, 4C, and 4D illustrate example strip electrodes in contact withexample combinations of the contact jaws of FIG. 4A, including gapsbetween adjacent contact jaws and lateral extensions of the stripelectrodes beyond the contact jaws, in accordance with aspects of thisdisclosure.

FIG. 5 is another view of the example adjustable head clamping plate ofFIG. 3, illustrating an example implementation of a contact jaw, thecontact pressure adjuster 328 for the contact jaw, and the strip lockpreventer for the contact jaw, in accordance with aspects of thisdisclosure.

FIG. 6 illustrates another view of the contact pressure adjuster and thestrip lock preventer of FIGS. 3 and 5, in accordance with aspects ofthis disclosure.

FIG. 7 is a perspective view of an example implementation of the reargranular flux delivery device of FIG. 1, in accordance with aspects ofthis disclosure.

FIG. 8 illustrates the rear granular flux delivery device of FIG. 7including an example implementation of the chute divider, in accordancewith aspects of this disclosure.

FIGS. 9A, 9B, and 9C illustrates the rear granular flux delivery deviceof FIG. 7 including another example implementation of a chute divider,in accordance with aspects of this disclosure.

FIG. 10 illustrates an example implementation of the strip feeder ofFIG. 1, in accordance with aspects of this disclosure.

FIGS. 11A, 11B, and 11C illustrate an example implementation of anadjustable strip guide for the strip feeder of FIGS. 1 and 10, inaccordance with aspects of this disclosure.

FIG. 11D illustrates another example implementation of an adjustablestrip guide for the strip feeder of FIGS. 1 and 10, in which all of thebearings are adjustable within slots that extend across a width of astrip feed path, in accordance with aspects of this disclosure.

FIG. 12 illustrates another example view of the adjustable strip guideof FIGS. 11A, 11B, and 11C including the drive roller, in accordancewith aspects of this disclosure.

FIG. 13 illustrates an example implementation of adjustable pressureroller assemblies for the strip feeder of FIGS. 1 and 10, in accordancewith aspects of this disclosure.

FIG. 14 illustrates another view of the example adjustable pressureroller assemblies of FIG. 13, including the drive roller, the adjustablepressure roller assemblies, and the pressure adjusters, in accordancewith aspects of this disclosure.

FIG. 15 illustrates an example implementation of the strip feeder ofFIGS. 1 and 10, in which the drive roller is equipped with a clutchadapter for connection to a drive shaft, in accordance with aspects ofthis disclosure.

FIG. 16 illustrates another view of the example drive roller and theexample clutch adapter of FIG. 15, in accordance with aspects of thisdisclosure.

DETAILED DESCRIPTION

Cladding heads are disclosed that may be used for ESSC and/or SASCmethods. Disclosed cladding heads have advantages over conventionalcladding heads, including enhancing the usability of the cladding heads.For example, compared to conventional cladding heads, disclosed examplecladding heads reduce the time and energy required to change the stripwidths used by the cladding heads. Where conventional cladding heads mayrequire at least partial deconstruction and/or rebuilding of thecladding head, disclosed examples enable changes of the strip widths byadjusting the position of one or more bearings in a strip feed path.Disclosed examples have improved longevity of components including driverollers, pressure rollers, and/or electrical contact pads. Additionaladvantages of disclosed examples are discussed herein.

Disclosed example granular welding flux delivery devices include ahopper having: an intake opening to receive granular welding flux; achute; and an output opening to output the granular welding flux to anelectroslag strip cladding process, a submerged arc welding process, ora submerged arc strip cladding process. Disclosed example granularwelding flux delivery devices further include a chute divider positionedwithin the chute to reduce an intake rate of granular material throughthe intake opening by reducing a cross-section of the chute based on adimension of the chute divider. Disclosed example granular welding fluxdelivery devices include an adjustable output cover attached to thechute proximate to the output opening to extend or retract a length ofthe chute by adjusting a location of the output opening along the chute.

In some examples, the chute divider is detachably attached to the chute.In some examples, the chute divider is replaceable by a second chutedivider having a different dimension to cause a different input rate ofthe granular material through the intake opening. In some examples, thechute divider includes a baffle extending longitudinally through thechute, where the baffle divides the chute into at least a first portionand a second portion, a removable insert to, when installed in theintake opening, block the first portion of the chute and a correspondingportion of the intake opening. In some examples, the second portion ofthe chute has a larger cross-section than the first portion of thechute.

In some examples, the chute tapers toward the output opening. In someexamples, the adjustable output cover is movable in a direction towardthe intake opening to increase an output area of the output opening. Insome such examples, the adjustable output cover, when moved in thedirection of the intake opening, increases at least one of a volume flowof the granular welding flux or a deposition area of the granularwelding flux.

In some examples, the adjustable output cover is movable in a directionaway from the intake opening to decrease an output area of the outputopening. In some such examples, the adjustable output cover, when movedin the direction away from the intake opening, decreases at least one ofa volume flow of the granular welding flux or a deposition area of thegranular welding flux. In some examples, the dimension of the chutedivider is modifiable to change the cross-section of the chute.

Disclosed example strip cladding systems include a cladding head todeliver a cladding strip to a workpiece and a granular welding fluxdelivery device to delivery granular welding flux adjacent the claddingstrip at the workpiece. The granular welding flux delivery deviceincludes a hopper having an intake opening to receive the granularwelding flux, a chute, and an output opening to output the granularwelding flux to an electroslag strip cladding process, a submerged arcwelding process, or a submerged arc strip cladding process. The granularwelding flux delivery device further includes a chute divider positionedwithin the chute to reduce an intake rate of granular material throughthe intake opening by reducing a cross-section of the chute based on adimension of the chute divider. The granular welding flux deliverydevice further includes an adjustable output cover attached to the chuteproximate to the output opening to extend or retract a length of thechute by adjusting a location of the output opening along the chute.

In some examples, the chute divider is replaceable by a second chutedivider having a different dimension to cause a different input rate ofthe granular material through the intake opening. In some examples, thechute divider includes a baffle extending longitudinally through thechute divider, where the baffle divides the chute into at least a firstportion and a second portion, and a removable insert to, when installedin the intake opening, block the first portion of the chute and acorresponding portion of the intake opening. In some such examples, thesecond portion of the chute has a larger cross-section than the firstportion of the chute.

In some examples, the chute tapers toward the output opening. In someexamples, the adjustable output cover is movable in a direction towardthe intake opening to increase an output area of the output opening. Insome such examples, the adjustable output cover, when moved in thedirection of the intake opening, increases at least one of a volume flowof the granular welding flux or a deposition area of the granularwelding flux.

In some examples, the adjustable output cover is movable in a directionaway from the intake opening to decrease at least one of an output areaof the output opening, a volume flow of the granular welding flux, or adeposition area of the granular welding flux. In some examples, thecladding head is configurable to deliver cladding strips of at leastthree incremental strip widths, where the dimension of the chute dividercorresponds to a first one of the at least three incremental stripwidths and cross-section of the chute corresponding to a widest one ofat least three incremental strip widths.

FIG. 1 is a block diagram illustrating an example strip cladding system100. The example strip cladding system 100 of FIG. 1 may be used toimplement SASC and/or ESSC strip cladding processes on a workpiece 102.The example strip cladding system 100 is capable of applying stripshaving different widths within a range of widths. As described in moredetail below, the example strip cladding system 100 of FIG. 1 includesfeatures that reduce potential downtime of the strip cladding system 100by, for example, reducing strip locking, reducing the time and effortrequired to change between strips of different widths, reducing wear oncomponents in the strip feeding and/or strip delivery path(s), and/orreducing strain placed on a drive system, compared to conventional stripcladding systems and/or strip cladding heads.

The example strip cladding system 100 of FIG. 1 includes a cladding head104, a strip feeder 106, a welding power source 108, and a forwardgranular flux delivery device 110. In some examples, such as performingSASC processes, the example strip cladding system 100 is furtherprovided with a rear granular flux delivery device 112.

The example cladding head 104 receives strip electrodes 114 from thestrip feeder 106, heats the strip electrode(s) 114, and delivers heatedstrip electrodes 116 to the workpiece 102. The example cladding head 104may be configured to heat and deliver strip electrodes 114 havingdifferent widths and/or thicknesses. In some examples disclosed herein,the cladding head 104 is adapted to use strip electrodes 114 ofdifferent widths by, for example, increasing a number of contact jawsused to heat the strip electrodes 114 as the width of the stripelectrode is increased. Conversely, in some examples one or more of thecontact jaws are disengaged (e.g., do not make contact) when the widthof the strip electrode does not require use of the one or more contactjaws.

The example strip feeder 106 receives the strip electrodes 114 from astrip electrode supply 118 (e.g., a roll or stack, manual feeding ofstrip electrodes 114, etc.). In some examples, the strip feeder 106drives the strip electrodes 114 through the cladding head 104 whilemaintaining an alignment of the strip electrodes 114. Like the claddinghead 104, the example strip feeder 106 of FIG. 1 is configurable to feedstrip electrodes 114 having different widths and/or thicknesses.

The cladding head 104 receives weld power 120 from the welding powersource 108. The welding power source 108 converts primary power 122 tothe weld power 120 for use by the cladding head 104 in resistive heatingand/or arc welding the strip electrodes 114 to the workpiece 102. Theexample welding power source 108 also provides drive power 124 to thestrip feeder 106 to enable the strip feeder 106 to drive the stripelectrodes 114 through the cladding head 104.

The example forward granular flux delivery device 110 and the examplerear granular flux delivery device 112 deliver granular welding flux 126to the workpiece 102 proximate to the heated strip electrode(s) 116. Theforward granular flux delivery device 110 delivers the granular weldingflux 126 ahead of the heated strip electrode(s), while the rear granularflux delivery device 112 delivers the granular welding flux 126 behindthe heated strip electrodes 116 in a direction of travel 128 of thecladding head 104. The forward granular flux delivery device 110 and theexample rear granular flux delivery device 112 receive the granularwelding flux 126 from a granular welding flux supply 130.

FIG. 2 is a partially exploded view of an example implementation of thestrip cladding system 100 of FIG. 1. As illustrated in FIG. 2, the stripcladding system 100 includes example implementations of the claddinghead 104, the strip feeder 106, the forward granular flux deliverydevice 110, and the rear granular flux delivery device 112. As describedin more detail below, some components illustrated in FIG. 2 are includedin both the cladding head 104 and the strip feeder 106. Theimplementation of FIG. 2 includes three independently adjustablepressure rollers and three independently adjustable contact jaws, andmay be used to apply strip electrodes having widths between 30millimeters and 90 millimeters (e.g., in 30 mm increments). In otherexamples, more or fewer pressure rollers and/or contact jaws may be usedto change the widths of the strip electrodes usable with the stripcladding system 100. As used herein, “independently adjustable pressure”refers to the adjustment of the pressure applied by one element notsubstantially impacting a pressure applied by a second element.Additionally or alternatively, the widths increments may be greater orless than the example 30 mm width increments of FIG. 2. While an exampleimplementation is illustrated in FIG. 2, one or more of the componentsshown in FIG. 2 may be combined, divided, re-arranged, and/or otherwisemodified.

The cladding head 104 of FIG. 2 includes a cladding head pressuresupport 202, a static cladding head clamping plate 204, an adjustablecladding head clamping plate 206, and contact plates 208. Collectively,the cladding head pressure support 202, the static cladding headclamping plate 204, the adjustable cladding head clamping plate 206, andthe contact plates 208 operate as contact jaws to apply welding-typepower to strip electrodes that are fed through the cladding head 104 bythe strip feeder 106.

The strip feeder 106 of FIG. 2 includes an upper strip guide 210, afeeder support 212, a drive roller 214, a drive roller clutch 216,pressure rollers 218, pressure adjusters 220, and a lower strip guide222. Strip electrodes are fed through the upper strip guide 210 to thedrive roller 214. The pressure rollers 218 are adjustable via thepressure adjusters 220 to provide a suitable pressure against the driveroller 214 to drive the strip electrodes through the cladding head 104to the workpiece 102 (e.g., without suffering from slipping of the driveroller). The example upper strip guide 210 and the example lower stripguide 222 are adjustable based on the width of the strip electrode, tokeep a consistent alignment of the strip electrode through the stripfeeder 106 and the cladding head 104.

FIG. 3 is a perspective view of an example implementation of thecladding head 104 of FIG. 1. The example view illustrated in FIG. 3includes the cladding head pressure support 202, the static claddinghead clamping plate 204, the adjustable cladding head clamping plate206, and the contact plates 208 in an assembled state.

As shown in FIG. 3, the adjustable cladding head clamping plate 206includes three fingers 302, 304, 306 connected to a pivot 308. Thefingers 302, 304, 306 and the static cladding head clamping plate 204function as contact jaws 310, 312, 314 having the contact plates 208 aselectrical contacts. The contact jaws 310, 312, 314 make electricalcontact with the strip electrodes. The example fingers 302, 304, 306 arelevered arms having the pivot 308 as a fulcrum.

For the contact jaw 310, a first contact plate 316 is attached to thefinger 302, and a second contact plate 318 is attached to the staticcladding head clamping plate 204 opposite the first contact plate 316.The contact jaws 312, 314 are similar to the contact jaw 310, andinclude corresponding contact plates 320, 322, 324, 326. For the contactjaw 312, the first contact plate 320 is attached to the finger 304, anda second contact plate 322 is attached to the static cladding headclamping plate 204 opposite the first contact plate 320. For the contactjaw 314, the first contact plate 324 is attached to the finger 306, anda second contact plate 326 is attached to the static cladding headclamping plate 204 opposite the first contact plate 324. The contactplates 316, 318, the contact plates 320, 322, and/or the contact plates324, 326 provide welding power (e.g., from the welding power source 108of FIG. 1) to the cladding strip(s) that are driven between the firstand second contact plates 316, 318. In some examples, the contact plates316-326 are constructed with a hard-wearing copper.

The first finger 302 of the cladding head 104 is coupled to a firstcontact pressure adjuster 328. The first contact pressure adjuster 328is configured to set a first pressure applied to the cladding strip bythe first and second contacts 316, 318 of the first contact jaw 310. Inthe example implementation of FIG. 3, the contact pressure adjuster 328applies a force to the finger 302 via the cladding head pressure support202, which is mechanically coupled (e.g., rigidly coupled) to the pivot308 and enables the first contact pressure adjuster 328 to apply theforce. In the example of FIG. 3, the contact pressure adjuster 328includes a spring 330 that biases a piston 332 connected to the finger302. The force applied by the spring 330, via the piston 332, the finger302, and the pivot 308, forces the first contact 316 of the contact jaw310 toward the second contact 318. The contact pressure adjuster 328also includes a spring compressor 334 that applies an adjustablecompressive force to the spring 330 to set the bias or force. Forexample, the spring compressor 334 may be a threaded cap on the piston332, which may be tightened to increase the compressive force on thespring 330 and, as a result, increase the opposing force applied by thespring to the piston 332 via the spring compressor 334.

The example piston 332 includes one or more visual indicators 346 of thepressure or compressive force applied by the spring compressor 334. Anexample visual indicator 316 includes markings on the piston 332 thatcorrespond to different pressures. The visual indicators 346 enable anoperator of the spring compressor 334 to obtain a consistent pressureacross multiple contact pressure adjusters 328 by, for example, settingthe spring compressors 334 for each of the multiple contact pressureadjusters 328 using the visual indicators 346 to identify the desiredpressure settings (e.g., setting the same pressure setting on eachcontact pressure adjuster 328 using the same visual indicator 346).

A strip lock preventer 336 limits the pressure applied by the first andsecond contacts 316, 318 to the cladding strip(s) to be less than athreshold pressure that could cause the cladding strip(s) to be lockedin place between the first and second contacts 316, 318. In someexamples, the threshold pressure is greater than a pressure needed tomake reliable electrical contact between the first and second contacts316, 318 and the cladding strip. The pressure applied by the contactsreduces or eliminates electrical arcing between the first and secondcontacts 316, 318 and the cladding strip. In the example of FIG. 3, thestrip lock preventer 336 limits the pressure applied to the finger 302by the spring 330. For example, the strip lock preventer 336 may includea pin through the piston 332 and/or a rigid cap on the spring compressor334, which limits the extent to which the spring compressor 334 can bethreaded onto the threaded piston 332 and, thus, the amount ofcompression the spring compressor 334 applies to the spring 330.

Similarly, a contact pressure adjuster 338 applies sets a pressureapplied to the strip electrode by the contact jaw 312 and a contactpressure adjuster 340 applies sets a pressure applied to the stripelectrode by the contact jaw 314. A strip lock preventer 342 limits thepressure applied by the contact jaw 312, and a strip lock preventer 344limits the pressure applied by the contact jaw 314.

While higher compressive forces are desirable to reduce electricalcontact bouncing and reduction in cladding quality, strip locking causessubstantial disruption to an ongoing strip cladding process and, in someinstances, damage to the strip cladding system 100. As used herein,strip locking occurs when the contact jaw(s) 310, 312, 314 lock theelectrode strip in place by friction due to sufficiently highcompression on the electrode strip by the contact jaw(s) 310-314. Whenstrip locking occurs in conventional strip cladding devices, the stripelectrode is locked into position at the contact jaw(s), but the stripfeeder continues to feed the strip electrode(s) toward the contactjaw(s). As a result, the strip electrode may be deformed to relieve thecompressive force on the strip electrode applied by the drive roller(e.g., the drive roller 214 of FIG. 2), the drive roller may beginslipping against the strip electrode (e.g., causing premature wearand/or catastrophic damage to the drive roller), and/or other mechanicaleffects (e.g., component breakage) may result to relieve the mechanicalstress applied to the system 100.

The spring lock preventer 336 prevents the spring compressor 334 fromexceeding an upper limit on the compressive force of the contact plates316, 318. The upper limit of the compressive force is set to preventlocking of the electrode strip by the contact jaw 310 (alone or incombination with the other contact jaws 312, 314). Similarly, the springlock preventers 342, 344 limit the force applied by the contact jaws312, 314 to the strip electrodes. The ranges of pressures that can beapplied by the contact pressure adjusters 328, 338, 340 may beconfigured based on the contact plate material(s), the strip electrodematerial(s), the drive force applied to the strip electrode by the driveroller, the drive roller material(s), and/or the strip electroderigidity.

FIG. 4A is another view of the example cladding head 104 of FIG. 3,illustrating an example spacing between the contact jaws 310, 312, 314.The example contact jaws 310, 312, 314 are configured to apply weldingpower across a width of an electrode as the electrode passes between thecontact plates 316-326 of the contact jaws 310, 312, 314. That is,different ones of the contact jaws 310-314 apply the pressure and thewelding power to different sections of the strip electrode. One or moreof the contact jaws 310, 312, 314 are used to apply the welding powerbased on a width of the strip electrode. For example, any of the contactjaws 310, 312, or 314 may be used alone for a narrow strip electrode. Apair of the contact jaws 310 and 312 (or 312 and 314) may be used for astrip electrode that has a width that is wider than the width of any oneof the contact jaws 310, 312, 314. All of the contact jaws 310, 312, and314 may be used for a strip electrode having a maximum width permittedby the system 100.

In the example of FIG. 4A, the total width of the contact jaws 310, 312,314 used for a given strip electrode width is less than the stripelectrode width. In other words, the strip electrode extends laterallybeyond the outer edges of the contact jaws 310, 312, 314 that are usedto provide the welding power. Each of the contact jaws 310, 312, 314 hasa width of less than 29 mm and, in some examples, each of the contactjaws 310, 312, 314 has a width of 27 mm.

Additionally or alternatively, adjacent contact jaws 310 and 312 or 312and 314 are spaced apart laterally by more than a nominal distance. Forexample, adjacent contact jaws 310 and 312 or 312 and 314 are spaced atleast 1 mm apart and, in some examples, adjacent contact jaws are spaced3 mm apart. As shown in FIG. 4A, each of the contact jaws has a width of27 mm, and is separated from adjacent contact jaws by 3 mm. When astandard 30 mm wide strip electrode 402 is applied using the examplecladding head 104, only the contact jaw 310 is used to apply the weldingpower, and the strip electrode 402 laterally extends over the contactjaw 310 by 1.5 mm on each side of the strip electrode 402 (FIG. 4B).When a standard 60 mm wide strip electrode 404 is applied using theexample cladding head 104, only the contact jaws 310 and 312 are used toapply the welding power, and the strip electrode 404 laterally extendsover the contact jaw 310 by 1.5 mm on one side of the strip electrodeand laterally extends over the side of the contact jaw 312 by 1.5 mm onthe other side of the strip electrode 404 (FIG. 4C). When a standard 90mm wide strip electrode 406 is applied using the example cladding head104, the contact jaws 310, 312, and 314 are used to apply the weldingpower, and the strip electrode 406 laterally extends over the contactjaw 310 by 1.5 mm on one side of the strip electrode 460 and laterallyextends over the side of the contact jaw 314 by 1.5 mm on the other sideof the strip electrode 406 (FIG. 4D).

The pressures applied by the contact jaws 310, 312, 314 areindependently adjustable via the respective contact pressure adjusters328, 338, 340. As a result, the appropriate pressures can be appliedconsistently across the strip electrode, which provides a more reliableapplication of weld current to the strip electrode relative to using asingle pressure across the strip electrode (e.g., by reducing oreliminating mechanical bouncing between the strip electrode and thecontacts 316-326) and/or applying the pressure regardless of the stripelectrode width. In some examples, the pressure adjusters 328, 338, 340substantially prevent or substantially eliminate mechanical bouncing. Asused herein, substantial prevention and/or substantial elimination(e.g., substantial prevention of bouncing) refers to prevention orelimination (e.g., substantial prevention of bouncing) under ratedoperation conditions (e.g., in the absence of shock and/or vibration atthe cladding head 104 that exceeds rated levels). Additionally, thecontact jaws 310, 312, and/or 314 can be disengaged when not being usedto apply the weld power to the electrode. For example, if a 60 mmelectrode or a 30 mm electrode are used in the example system 100, thepressure applied by the contact jaw 312 is relieved by the contactpressure adjuster 340 to improve the operating life of the correspondingcontact plates 324, 326.

By using contact jaws 310, 312, 314 that have widths less than the stripelectrode width, the contact plates 316-326 are prevented from cominginto direct contact during operation, which reduces wear on the contactplates 316-326. A strip guide may be used to feed the cladding stripthrough the contact jaw(s) 310, 312, 314 such that the cladding striplaterally extends from the contact jaw(s) by between 0 millimeters and 3millimeters on a first lateral side and between 0 millimeters and 3millimeters on a second lateral side. However, other distances may beused provided that the portions of the cladding strip that are not incontact with any of the contact plates 316-326 are adequately heated forthe cladding process.

FIG. 5 is another view of the example adjustable cladding head clampingplate 206 of FIG. 3, illustrating an example implementation of a contactjaw 310, the contact pressure adjuster 328 for the contact jaw 310, andthe strip lock preventer 336 for the contact jaw 310. FIG. 6 illustratesanother view of the contact pressure adjuster 328 and the strip lockpreventer 336 of FIGS. 3 and 5. As illustrated in FIG. 5, the strip lockpreventer 336 may be implemented by providing a portion of the piston330 with a larger diameter. The portion of the piston 332 implementingthe strip lock preventer 336 corresponds to a maximum desiredcompression of the spring 330 against a support structure 502 when thespring compressor 334 has been tightened until an inner surface of thespring compressor 334 abuts the strip lock preventer 336.

As the pressure is increased via the spring compressor 334, the spring330 applies greater force to push the spring compressor 334 and, thus,the piston 332, in a direction 504 away from the support structure 502.The piston 332 is connected to the finger 302, and the pivot 308reverses the force on the piston 332 in the direction 504 to a force onthe contact plate 316 in a direction 506 toward the contact plate 508(e.g., to close the contact jaw 310 and make consistent electricalcontact between the contact plates 316, 318).

FIG. 7 is a perspective view of an example implementation of the reargranular flux delivery device 112 of FIG. 1. The example rear granularflux delivery device 112 includes a hopper 702 and an adjustable cover710. As described in more detail below, the rear granular flux deliverydevice 112 takes granular flux as input and is configurable to outputthe granular flux to a strip cladding process at different rates. Theexample rear granular flux delivery device 112 can be configured toregulate the granular flux input rate to the hopper 702, the granularflux output rate from the hopper 702, and/or a dispersion are of thegranular flux output from the hopper 702.

The example hopper 702 has an intake opening 704, a chute 706, and anoutput opening 708. The intake opening 704 receives the granular weldingflux (e.g., from the granular welding flux supply 130). The outputopening 708 outputs the granular welding flux from the chute 706 to anelectroslag strip cladding process, a submerged arc welding process, ora submerged arc strip cladding process.

The example rear granular flux delivery device 112 further includes achute divider positioned within the chute 706 to reduce an intake rateof granular flux through the intake opening 704. FIG. 8 illustrates therear granular flux delivery device 112 of FIG. 7 including an exampleimplementation of the chute divider 802. The example chute divider 802is a detachable rigid strip that is attached to the chute 706 (e.g.,near the intake opening 704). The dimensions of the rigid stripdetermine the extent to which the chute divider 802 blocks or reducesthe cross-section of the chute 706. For example, a first chute divider802 has first dimensions (e.g., angle, length, etc.) to block a largerportion of the cross-section of the chute 706 and a second chute divider804 has second dimensions (e.g., angle, length, etc.) to block a smallerportion of the cross-section of the chute 706. Thus, the second chutedivider 804 may be installed to reduce a granular flux deposition ratefrom a maximum flow rate of the hopper 702, and the first chute divider802 may be installed to further reduce the granular flux depositionrate. The chute dividers 802, 804 are interchangeable (e.g.,replaceable).

Returning to FIG. 7, the example rear granular flux delivery device 112also includes an adjustable output cover 710 attached to the chute 706proximate to the output opening 708. The adjustable output cover 710 mayextend and/or retract a length of the chute 706 by adjusting a locationof the output opening 708 along the chute 706. The adjustable outputcover 710 includes slots 712 that slide along tightening screws 714. Thetightening screws 714 can be loosened to permit the adjustable outputcover 710 to slide (e.g., extend and/or retract) by sliding the slots712 along the tightening screws 714. When a desired position of theadjustable output cover 710 is reached, the tightening screws 714 may betightened to fix the adjustable output cover 710 in the position.

In the example of FIG. 7, the chute 706 tapers toward the output opening708. Thus, by moving the adjustable output cover 710 toward the intakeopening 704, the output opening 708 has a larger cross-section (e.g.,higher deposition rate, lower resistance to granular flux flow at theoutput opening 708). Additionally, having a larger cross-section at theoutput opening 708 may increase a deposition area of the granular fluxat the workpiece 102. Conversely, moving the adjustable output cover 710away from the intake opening 704 results in the output opening 708having a smaller cross-section (e.g., lower deposition rate, higherresistance to granular flux flow at the output opening 708) and/or asmaller deposition area of the granular flux at the workpiece 102.

FIGS. 9A, 9B, and 9C illustrates the rear granular flux delivery device112 of FIG. 7 including another example implementation of a chutedivider. The example chute divider 900 of FIG. 9A includes one or morebaffles 902, 904 extending longitudinally through the chute 706. Theexample baffles 902, 904 divide the chute 706 into three differentportions (e.g., the baffles sub-divide the cross section of the chute706). In some other examples, a single baffle divides the chute 706 intofirst and second portions. In other examples, additional baffles dividethe chute 706 into additional portions. The example chute divider 900further includes a removable insert 906, 908. A first removable insert906 is shown installed (e.g., inserted) in FIG. 9B, and a secondremovable insert 908 is shown inserted in FIG. 9C. When installed in theintake opening 704, the inserts 906, 908 block portion(s) of the chute706 and corresponding portion(s) of the intake opening 704. For example,the removable insert 906 blocks one of the three portions of the chute706 and the intake opening 704, resulting in a lower granular fluxdelivery rate than if the entire hopper 702 is used. The removableinsert 908 blocks two of the three portions of the chute 706 and theintake opening 704, resulting in a lower granular flux delivery ratethan if the first removable inserter 906 is used.

As illustrated in FIGS. 9A-9C, the portions of the chute 706 may havedifferent cross-sections. For example, when one of the portions of thechute 706 is used as shown in FIG. 9C, the portion of the chute 706 hasa cross-section greater than ⅓ of the cross-section of the chute 706.Using the example strip electrode sizes of 30 mm, 60 mm, and 90 mm, thewidth of the single portion of the chute 706 (e.g., when the insert 908is installed) is more than 30 mm to permit deposition of the granularflux on the sides of the 30 mm strip path at the workpiece 102. Use ofthe second portion of the chute 706 (in addition to the first portion)(e.g., when the insert 906 is installed) increases the width of theoutput opening 708 by, for example 30 mm to permit deposition of thegranular flux on the sides of the 60 mm strip path at the workpiece 102.Similarly, use of the full cross-section of the chute 706 (e.g., theinserts 906, 908 are removed) further increases the width of the outputopening 708 by, for example, 60 mm more than the width of the firstportion to permit deposition of the granular flux on the sides of the 90mm strip path at the workpiece 102.

FIGS. 9A-9C also illustrate an example of the adjustable output cover710 in a position closer to the intake opening 704. As mentioned above,positioning the adjustable output cover 710 closer to the intake opening704 (e.g., compared to the position illustrated in FIG. 7) increases thecross-section of the output opening 708 and permits a higher depositionrate of the granular flux through the output opening 708 and/or a largerdeposition area of the granular flux at the workpiece 102.

FIG. 10 illustrates an example implementation of the strip feeder 106 ofFIGS. 1 and 2. The example strip feeder 106 illustrated in FIG. 10includes the upper strip guide 210, the feeder support 212, the driveroller 214, the drive roller clutch 216, the pressure rollers 218, thepressure adjusters 220, and the lower strip guide 222.

The drive roller 214 advances cladding strip(s) along a strip feed path1002 to the cladding head 104 (e.g., through the contact plates 316-326of the cladding head 104 of FIG. 1). The pressure rollers 218 and thepressure adjusters 220 press the cladding strip(s) traveling along thestrip feed path 1002 against the drive roller 214, thereby enhancing thegrip of the drive roller 214 on the cladding strip(s) and reducing oreliminating slippage between the drive roller 214 and the claddingstrips. In the example of FIG. 10, the drive roller 214 is a hardenedand knurled drive roller. However, other surface patterns and/ormaterials may be used.

The example pressure rollers 218 are positioned along the strip feedpath 1002 opposite different sections of the drive roller (e.g.,laterally across the strip feed path 1002). Different numbers of thepressure rollers 218 may be engaged based on a width of the claddingstrip. For example, one of the pressure rollers 218 may be used forstrip electrodes having a minimum strip width and all of the pressurerollers 218 may be used for strip electrodes having a maximum stripwidth.

The pressure adjusters 220 set pressures that are applied to thecladding strips by the corresponding ones of the pressure rollers 218.For example, a first one of the pressure adjusters 220 sets a firstpressure applied to the cladding strip by a first one of the pressurerollers 218 and the first lateral section of the drive roller 214, asecond one of the pressure adjusters 220 sets a second pressure appliedto the cladding strip by a second one of the pressure rollers 218 and asecond lateral section of the drive roller 214, and a third one of thepressure adjusters 220 sets a third pressure applied to the claddingstrip by a third one of the pressure rollers 218 and a third lateralsection of the drive roller 214. The pressure adjusters 220 areadjustable to disengage one or more of the pressure rollers 218 when thecladding strip has a width that does not require use of thecorresponding pressure rollers 218.

FIGS. 11A, 11B, and 11C illustrate an example implementation of anadjustable strip guide 1100 for the strip feeder 106 of FIGS. 1 and 10.In the examples of FIGS. 11A, 11B, and 11C, the adjustable strip guide1100 is reconfigurable to guide cladding strips of different widthswithout deconstruction and/or rebuilding of the strip feeder 106. Theexample adjustable strip guide 1100 guides cladding strip(s) along thestrip feed path 1002 (e.g., between the drive roller 214 and thepressure roller(s) 218. FIG. 12 illustrates another example view of theadjustable strip guide 1100 of FIGS. 11A, 11B, and 11C including thedrive roller 214.

As the drive roller 214 advances a cladding strip along the strip feedpath 1002 to the cladding head 104 (e.g., through the contact plates316-328), a first bearing 1102 and a second bearing 1104 located alongthe strip feed path 1002 laterally guide the cladding strip (e.g.,prevent deviation or movement of the cladding strip in a directionlateral to the strip feed path 1002). The first and second bearings1102, 1104 are aligned in a direction of the strip feed path 1002 andare located at different positions along the strip feed path 1002. Forexample, the first bearing 1102 is located prior to the drive roller 214in the direction of travel of the electrode strips along the strip feedpath 1002 and the second bearing is located after the drive roller 214in the direction of travel of the electrode strips along the strip feedpath 1002. In the example of FIGS. 11A-11C, the first and secondbearings 1102, 1104 have fixed lateral positions.

The example adjustable strip guide 1100 includes an adjustable bearing1106 to guide the cladding strip. A strip width adjuster 1108 permitsadjustment of the position of the adjustable bearing 1106 across thestrip feed path 1002 to accommodate strips of different widths and/or tosecure the adjustable bearing 1106 against movement across the stripfeed path 1002. The strip width adjuster 1108 permits adjustment of theposition of the adjustable bearing 1106 to accommodate strip widths upto an upper strip width limit of the drive roller 214 and/or to a lowerstrip width limit of the drive roller 214.

The example adjustable strip guide 1100 also includes a secondadjustable bearing 1110 and a second strip width adjuster 1112. Thesecond strip width adjuster 1112 is similar to the strip width adjuster1108, but is located after the drive roller 214 in the direction oftravel of the electrode strips along the strip feed path 1002.

As illustrated in FIGS. 11A-11C and 12, the example strip width adjuster1108 includes guide rails 1114, 1116 that have slots 1118, 1120extending across at least part of the strip feed path 1002. The stripwidth adjuster 1108 also includes a fastener 1122 to fix the position ofthe adjustable bearing 1106 along the slot 1118, 1120. In the example ofFIGS. 11A-11C and 12, the guide rails 1114, 1116 are positioned onopposite sides of the adjustable bearing 1106 such that the strip feedpath 1002 extends between the guide rails 1114, 1116. The bearing 1106is supported on a bolt 1124 extending through the slots 1118, 1120, andthe fastener 1122 includes a nut or other tightening mechanism that maybe tightened to secure the bolt 1124 and the adjustable bearing 1106 atone location along the slots 1118, 1120.

Similarly, the example strip width adjuster 1112 includes slots 1126,1128, a fastener 1130, a bolt 1132. In the example of FIGS. 11A-11C and12, the slots 1126, 1128 are part of static cladding head clamping plate204 and the lower strip guide 222 of FIG. 2, instead of having dedicatedguide rails. However, the strip width adjuster 1112 may be implementedusing guide rails as with the strip width adjuster 1108.

The bolt 1132 supports the adjustable bearing 1110 and may be positionedalong the slots 1126, 1128. The fastener 1130 is tightened to secure thebolt 1132 and the adjustable bearing 1110 at one position along theslots 1126, 1128.

In some examples, the slots 1118, 1120 and/or the slots 1126, 1128 mayinclude one or more grooves along the slots 1118, 1120 to reduce lateralmovement of the adjustable bearing 1106 when the bolt 1124 is adjustedinto the groove and the fastener 1122 is tightened. Additionally oralternatively, the slots 1118, 1120 are aligned with the slots 1126,1128 to align the adjustable bearings 1106, 1110 in the direction oftravel of the strip electrode along the strip feed path 1002, and thegrooves improve the alignment of the adjustable bearing 1106 with theadjustable bearing 1110.

In the example of FIGS. 11A-11C and 12, the bearings 1102 and 1104 arealigned in the direction of travel of the strip electrode along thestrip feed path 1002, the adjustable bearings 1106 and 1110 are alignedin the direction of travel of the strip electrode along the strip feedpath 1002, the bearing 1102 and the adjustable bearing 1106 are alignedacross the strip feed path 1002, and the bearing 1104 and the adjustablebearing 1110 are aligned across the strip feed path 1002. However, inother examples, one or more of the bearings 1102, 1104, 1106, and 1110may be staggered (e.g., placed at different locations) in the directionof travel of the strip electrode along the strip feed path 1002.Additionally or alternatively, while the bearings 1102, 1104 have astatic position on one side of the strip feed path 1002 and theadjustable bearings 1106, 1110 can be adjusted on the other side of thestrip feed path 1002 to change the width of the strip feed path 1002, inother examples the bearings 1102, 1104 are at fixed positions on theopposite side of the strip feed path 1002 from the illustrated exampleand the adjustable bearings 1106, 1110 are on opposite side of the stripfeed path 1002 from the illustrated example.

In still other examples, such as the example configuration illustratedin FIG. 11D, any or all of the bearings 1102, 1104, 1106, 1110 areadjustable bearings that can be positioned at different locations acrossthe strip feed path 1002 to select different alignments of the stripelectrodes in the strip feed path 1002 (e.g., aligned on the left sideof the strip feed path 1002, aligned on the right side of the strip feedpath 1002, and/or aligned between the two sides of the strip feed path1002). Using adjustable bearings for all of the bearings 1102, 1104,1106, 1110 also enables use of a desired portion of the drive roller 214and/or changing of the ones of the contact jaws 310-314 that are used toprovide the welding power to the strip electrodes.

In the example of FIG. 11D, the guide rails 1114, 1116 and the slots1118, 1120, and/or the slots 1126, 1128, extend across the entirety ofthe strip feed path 1002. The bearings 1102 and 1106 are both adjustablewithin the slots 1118, 1120 via corresponding bolts and fasteners.Similarly, the bearings 1104 and 1110 are adjustable within the slots1126, 1128 via corresponding bolts and fasteners.

In contrast to conventional cladding systems, the strip width adjuster1108 permits use of different strip widths adjustment of the position ofthe adjustable bearing 1106 without deconstruction of the strip feeder106 or the cladding head 104. Instead, the example strip width adjusters1108, 1112 enable movement of the adjustable bearings 1106, 1110 vialoosening of the fixing mechanism (e.g., the fasteners 1122, 1130),sliding of the bolts 1124, 1132 along the slots 1118, 1120, 1126, 1128,and tightening of the fixing mechanism (e.g., the fasteners 1122, 1130).

FIG. 13 illustrates an example implementation of adjustable pressureroller assemblies 1302, 1304, 1306 for the strip feeder 106 of FIGS. 1and 10. In the example of FIG. 13, the pressures applied by theadjustable pressure roller assemblies 1302, 1304, 1306 are individuallyand independently adjustable via respective pressure adjusters 1308,1310, 1312. The example adjustable pressure roller assemblies 1302,1304, 1306 and the example pressure adjusters 220 are illustrated inFIG. 13 in a partially exploded view. FIG. 14 illustrates another viewof the example adjustable pressure roller assemblies 1302, 1304, 1306 ofFIG. 13, including the drive roller 214, the adjustable pressure rollerassemblies 1302, 1304, 1306, and the pressure adjusters 1308, 1310,1312.

The pressure roller assemblies 1302, 1304, 1306 are positioned along thestrip feed path 1002 of FIG. 10. The first pressure roller assembly 1302is positioned along the strip feed path 1002 opposite a first section1314 of the drive roller 214, the second pressure roller assembly 1304is positioned along the strip feed path 1002 opposite a second section1316 of the drive roller 214, and the third pressure roller assembly1304 is positioned along the strip feed path 1002 opposite a thirdsection 1318 of the drive roller 214. The pressure roller assemblies1302, 1304, 1306 are capable of applying substantially even pressureagainst strip electrode(s) moving through the strip feed path 1002 andthe drive roller 214.

The pressure roller assembly 1302 includes a pressure roller 1320, whichis coupled to a roller housing 1322. The roller housing 1322 isrotatably coupled to the example feeder support 212 that also supportsthe drive roller 214. The roller housing 1322 is permitted to rotate toengage and/or disengage the pressure applied by the pressure roller 1320to the strip electrode and the drive roller 214. The pressure roller1320 is permitted to rotate within the roller housing 1322 (e.g., as thestrip electrode traverses the strip feed path 1002 in contact betweenthe pressure roller 1320 and the drive roller 214.

The pressure adjuster 1308 applies pressure to a surface 1324 of theroller housing 1322, which pushes the pressure roller 1320 toward thedrive roller 214 and applies a corresponding pressure to the stripelectrode traveling through the strip feed path 1002. The pressureadjuster 1308 includes a finger 1326 to contact the first roller housing1322, a spring 1328 to bias the finger 1326 toward the first rollerhousing 1322, and a spring compressor 1330 to apply a compressive forceto the spring 1328 to set the bias of the finger 1326 toward the rollerhousing 1322. The example pressure adjuster 1308 is attached to thefeeder support 212, which also supports the pressure roller assemblies1302-1306. In the example of FIGS. 13 and 14, the spring compressor 1330is a knob or nut that may be screwed to increase the compressive forcebetween the spring compressor 1330 and the finger 1326.

The pressure roller assemblies 1304, 1306 are similar or identical tothe pressure roller assembly 1302. Similarly, the pressure adjusters1310, 1312 are similar or identical to the pressure adjuster 1308, andapply respective pressures to the pressure roller assemblies 1304, 1306.The pressure roller assembly 1304 includes a pressure roller 1332, aroller housing 1334, and a surface 1336 that is contacted by a finger1338 of the pressure adjuster 1310 to set the pressure applied by thepressure roller 1332. The pressure roller assembly 1306 includes apressure roller 1340, a roller housing 1342, and a surface 1344 that iscontacted by a finger 1346 of the pressure adjuster 1312 to set thepressure applied by the pressure roller 1340. The pressure adjuster 1310includes a spring 1348 to bias the finger 1338 toward the pressureroller assembly 1304 and a spring compressor 1350 to set the pressureapplied by the finger 1338 via the spring 1348. The example pressureadjuster 1312 includes a spring 1352 to bias the finger 1346 toward thepressure roller assembly 1306 and a spring compressor 1354 to set thepressure applied by the finger 1346 via the spring 1352. The pressuresapplied by the pressure adjusters 1308, 1310, 1312 are independentlyadjustable. That is, the pressure set via the pressure adjuster 1308 canbe different that the pressure set via either of the pressure adjusters1310, 1312.

Additionally or alternatively, the pressure adjusters 1308-1312 areadjustable to disengage the pressure roller assemblies 1302-1306 fromthe drive roller 214 when the cladding strip has a width that uses fewerthan all of the sections 1314-1318 of the drive roller 214. For example,if the strip electrode width corresponds to the section 1314 of thedrive roller 214, the pressure adjusters 1310, 1312 may disengage thepressure rollers 1332, 1340 from the sections 1316, 1318 of the driveroller 214.

In some examples, the strip feeder 106 supports strip electrodes havingone of multiple incremental strip widths (e.g., using a 30 mmincremental width such as 30 mm strips, 60 mm strips, 90 mm strips, 120mm strips, 150 mm strips, etc., and/or another incremental strip width).For strip electrodes having one of the multiple incremental stripwidths, the pressure rollers 1320, 1332, 1340 apply symmetric pressureacross a width of the cladding strip by selectively setting the pressureadjusters to apply the respective pressures based on the incrementalstrip width of the strip electrode being used. The symmetric pressureapplied by the pressure rollers 1320, 1332, 1340 (and/or a subset of thepressure rollers 1320, 1332, 1340 based on the strip width) provides abalanced feeding force to reduce or prevent misalignment of the stripelectrode at the cladding head. For example, if a 30 mm strip width isused, the pressure roller 1320 applies a symmetric pressure to the strip(e.g., to the center of the strip width) and the pressure rollers 1332,1340 are disengaged. If a 60 mm strip width is used, the pressurerollers 1320, 1332 apply a symmetric pressure to the strip (e.g., atequal distances from the center of the strip width) and the pressureroller 1340 is disengaged. If a 90 mm strip width is used, the pressurerollers 1320, 1332, 1340 apply a symmetric pressure to the strip (e.g.,at equal distances from the center of the strip width and at the centerof the strip width). If the strip feeder 106 includes four pressurerollers and corresponding pressure adjusters to support a 120 mm stripwidth, all four pressure rollers apply a symmetric pressure to the strip(e.g., at equal pairs of distances from the center of the strip width).Additional strip widths may be supported by adding further pressurerollers and pressure adjusters.

While an example implementation of the pressure adjusters 1308, 1310,1312 are illustrated in FIGS. 13 and 14, other implementations and/orconfigurations may be used. For example, the springs 1328, 1348, 1352may be replaced by other biasing elements. Other shapes and/or sizes ofthe fingers 1326, 1338, 1346 may be used, and/or the fingers 1326, 1338,1346 may be omitted in favor of direct contact between the springs 1328,1348, 1352 (or other biasing element(s)) and the pressure rollerassemblies 1302-1306. The spring compressors 1330, 1350, 1354 may bereplaced with different components to increase, decrease, and/or relievethe pressure applied to the pressure rollers 1320, 1332, 1340. Thespring compressors 1330, 1350, 1354 may increase or decrease thecompression on the springs 1328, 1348, or 1352 by, for example, movingthe position of the knob, screw, or nut relative to a fixed location(e.g., relative to the feeder support 212) and/or by extending and/orretracting the fingers 1326, 1338, 1346 relative to a location at whichthe springs 1328, 1348, 1352 apply pressure. The example pressureadjusters 1308, 1310, 1312 may have visible pressure scales (e.g.,graded scales) such that an operator of the cladding head can see thepressure level being applied on each of the pressure adjusters. Theexample visible scales enable an operator to apply a same level ofpressure for each pressure roller being used (which may not be all ofthe available pressure rollers, based on the width of the stripelectrode).

Example pressure roller assemblies 1302-1306 are illustrated in FIGS. 13and 14. However, other implementations and/or configurations may beused. For example, while the roller housings 1322, 1334, 1342 are usedin the illustrated example to support the pressure rollers 1320, 1332,1340 and/or provide leverage for the pressure applied by the pressureadjusters 1308, 1310, 1312, other configurations of the roller housings1322, 1334, 1342 may be used, and/or the pressure rollers 1320, 1332,1340 may be integrated into the pressure adjusters 1308-1312 such thatthe pressure adjusters 1308-1312 include a structure to support thepressure rollers 1320, 1332, 1340.

FIG. 15 illustrates an example implementation of the strip feeder 106 ofFIGS. 1 and 10, in which the drive roller 214 is equipped with a clutchadapter 1502 for connection to a drive shaft 1504. FIG. 16 illustratesanother view of the example drive roller and the example clutch adapterof FIG. 15. The example clutch adapter 1502 may be any type ofdetachable clutch configured to connect an interface of the drive roller214 to an interface of the drive shaft 1504. The example drive shaft1504 is driven by a power source (e.g., the welding power source 108 ofFIG. 1, such as an engine driven power source and/or a power supply thatconverts primary power to, among other things, rotational power to drivethe drive roller 214).

Use of the clutch adapter 1502 of FIG. 15 reduces stress on the driveshaft 1504 by removing the drive roller 214 as a vertical load on thedrive shaft 1504. As used herein, the term “vertical” refers to adirection parallel to the gravitational pull of the earth. Instead, theweight of the drive roller 214 is supported via the feeder support 212,and the clutch adapter 1502 couples the drive roller 214 to the driveshaft 1504 such that the drive shaft 1504 does not support a substantialamount of the weight of the drive roller 214. The example clutch adapter1502 reduces or eliminates line-up variances between the drive roller214 and the drive shaft 1504, thereby reducing motor axle fatigue and/orbearing wear due to out of line loads.

As utilized herein, “and/or” means any one or more of the items in thelist joined by “and/or”. As an example, “x and/or y” means any elementof the three-element set {(x), (y), (x, y)}. In other words, “x and/ory” means “one or both of x and y”. As another example, “x, y, and/or z”means any element of the seven-element set {(x), (y), (z), (x, y), (x,z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one ormore of x, y and z”. As utilized herein, the term “exemplary” meansserving as a non-limiting example, instance, or illustration. Asutilized herein, the terms “e.g.,” and “for example” set off lists ofone or more non-limiting examples, instances, or illustrations. Asutilized herein, circuitry is “operable” to perform a function wheneverthe circuitry comprises the necessary hardware and code (if any isnecessary) to perform the function, regardless of whether performance ofthe function is disabled or not enabled (e.g., by a user-configurablesetting, factory trim, etc.).

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. For example, block and/orcomponents of disclosed examples may be combined, divided, re-arranged,and/or otherwise modified. Therefore, the present method and/or systemare not limited to the particular implementations disclosed. Instead,the present method and/or system will include all implementationsfalling within the scope of the appended claims, both literally andunder the doctrine of equivalents.

What is claimed is:
 1. A granular welding flux delivery device,comprising: a hopper having an intake opening to receive granularwelding flux, a chute, and an output opening to output the granularwelding flux to an electroslag strip cladding process, a submerged arcwelding process, or a submerged arc strip cladding process; a chutedivider positioned within the chute to reduce an intake rate of granularmaterial through the intake opening by reducing a cross-section of thechute based on a dimension of the chute divider; and an adjustableoutput cover attached to the chute proximate to the output opening toextend or retract a length of the chute by adjusting a location of theoutput opening along the chute.
 2. The granular welding flux deliverydevice as defined in claim 1, wherein the chute divider is detachablyattached to the chute.
 3. The granular welding flux delivery device asdefined in claim 1, wherein the chute divider is replaceable by a secondchute divider having a different dimension to cause a different inputrate of the granular material through the intake opening.
 4. Thegranular welding flux delivery device as defined in claim 1, wherein thechute divider comprises: a baffle extending longitudinally through thechute, the baffle dividing the chute into at least a first portion and asecond portion; and a removable insert to, when installed in the intakeopening, block the first portion of the chute and a correspondingportion of the intake opening.
 5. The granular welding flux deliverydevice as defined in claim 4, wherein the second portion of the chutehas a larger cross-section than the first portion of the chute.
 6. Thegranular welding flux delivery device as defined in claim 1, wherein thechute tapers toward the output opening.
 7. The granular welding fluxdelivery device as defined in claim 6, wherein the adjustable outputcover is movable in a direction toward the intake opening to increase anoutput area of the output opening.
 8. The granular welding flux deliverydevice as defined in claim 7, wherein the adjustable output cover, whenmoved in the direction of the intake opening, increases at least one ofa volume flow of the granular welding flux or a deposition area of thegranular welding flux.
 9. The granular welding flux delivery device asdefined in claim 6, wherein the adjustable output cover is movable in adirection away from the intake opening to decrease an output area of theoutput opening.
 10. The granular welding flux delivery device as definedin claim 9, wherein the adjustable output cover, when moved in thedirection away from the intake opening, decreases at least one of avolume flow of the granular welding flux or a deposition area of thegranular welding flux.
 11. The granular welding flux delivery device asdefined in claim 1, wherein the dimension of the chute divider ismodifiable to change the cross-section of the chute.
 12. A stripcladding system, comprising: a cladding head to deliver a cladding stripto a workpiece; and a granular welding flux delivery device to deliverygranular welding flux adjacent the cladding strip at the workpiece, thegranular welding flux delivery device comprising: a hopper having anintake opening to receive the granular welding flux, a chute, and anoutput opening to output the granular welding flux to an electroslagstrip cladding process, a submerged arc welding process, or a submergedarc strip cladding process; a chute divider positioned within the chuteto reduce an intake rate of granular material through the intake openingby reducing a cross-section of the chute based on a dimension of thechute divider; and an adjustable output cover attached to the chuteproximate to the output opening to extend or retract a length of thechute by adjusting a location of the output opening along the chute. 13.The strip cladding system as defined in claim 12, wherein the chutedivider is replaceable by a second chute divider having a differentdimension to cause a different input rate of the granular materialthrough the intake opening.
 14. The strip cladding system as defined inclaim 12, wherein the chute divider comprises: a baffle extendinglongitudinally through the chute divider, the baffle dividing the chuteinto at least a first portion and a second portion; and a removableinsert to, when installed in the intake opening, block the first portionof the chute and a corresponding portion of the intake opening.
 15. Thestrip cladding system as defined in claim 14, wherein the second portionof the chute has a larger cross-section than the first portion of thechute.
 16. The strip cladding system as defined in claim 12, wherein thechute tapers toward the output opening.
 17. The strip cladding system asdefined in claim 16, wherein the adjustable output cover is movable in adirection toward the intake opening to increase an output area of theoutput opening.
 18. The strip cladding system as defined in claim 17,wherein the adjustable output cover, when moved in the direction of theintake opening, increases at least one of a volume flow of the granularwelding flux or a deposition area of the granular welding flux.
 19. Thestrip cladding system as defined in claim 16, wherein the adjustableoutput cover is movable in a direction away from the intake opening todecrease at least one of an output area of the output opening, a volumeflow of the granular welding flux, or a deposition area of the granularwelding flux.
 20. The strip cladding system as defined in claim 12,wherein the cladding head is configurable to deliver cladding strips ofat least three incremental strip widths, the dimension of the chutedivider corresponding to a first one of the at least three incrementalstrip widths and cross-section of the chute corresponding to a widestone of at least three incremental strip widths.